The entire world of metal forming
Components for sheet metal forming.
Table of contents / The entire world of metal forming
TABLE OF CONTENTS. The entire world of metal forming.
Welcome to the stamping plant. Welcome to Schuler.
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01 | Blanking lines
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07 | Tryout systems
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Cost-effective die startup with hydraulic and mechanical tryout presses, tryout centers, die turnover devices and simulators.
Individual solutions for your production.
08 | Lightweight technologies 02 | Hydraulic single presses
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Lines for press hardening (hot stamping), for cold and
Flexible presses for suppliers to the automobile
aluminum forming. For forming fiber-reinforced
industry, the household appliance industry and for
plastics and for hydroforming.
multiple metalforming applications.
09 | Process technology 03 | Mechanical single presses
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From simulation to series production.
Fast, flexible and cost-effective. C-frame presses, blanking presses, knuckle-joint presses, transfer &
10 | Systems large pipe manufacturinG
prog-die presses and servo presses.
Spiral pipe welding lines and system solutions for
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longitudinally welded pipes.
04 | Automation of single presses
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Coil lines, roll feed units, tri-axis transfer systems
11 | Locations and Schuler service
and destackers.
Technical customer service, components and
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accessories, project business, special services and
05 | Press lines
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used machines – on your doorstep, worldwide.
Hydraulic, hybrid, mechanical or servo press lines are fully automated system solutions.
06 | Automation of press lines
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Schuler press lines are equipped with the appropriate mechanization concept for the range of parts, productivity and space requirements.
Subject to technical modifications and amendments to content. 3
TABLE OF CONTENTS
Welcome to the stamping plant. Welcome to Schuler.
Transfer press with ServoDirect technology. 4
TABLE OF CONTENTS
Welcome to Schuler / The entire world of metal forming
As a world market leader in the technology of metal forming, Schuler offers presses, automation solutions, dies, process technology and service for the entire metal working industry and lightweight automotive construction. Its customers include automobile manufacturers and components suppliers as well as companies in the forging, domestic appliances, packaging, energy and electrical industries. Schuler is a leader in coin minting technology and produces system solutions for the aerospace, railway and large pipe industries. 5,500 people work for the company worldwide. The Schuler Group is present in 40 countries and is majority-owned by the Austrian Andritz-Group. We support you in all phases of a project, in planning new stamping plants through to integrating forming lines into existing structures. In close cooperation with your planning departments, technical purchasing, stamping plant and maintenance, we handle the installation, commissioning and production startup of lines and automation components. In this process, you also benefit from the extensive know-how of our project teams installations all over the world. We are also in daily contact with users of mechanical and hydraulic press technology regarding modernization, rebuilding, relocation and performance enhancements available for existing forming lines. Together we can find solutions that improve the cost-effectiveness of the stamping plant. This book provides you with an overview of our range of products and services. We are just right for the job wherever the highest parts quality, maximum plant availability and reliable press engineering is required day-in, day-out. From blanking and the forming process through stacking the finished components our lines offer the right answer to future requirements including increased use of high and extra high-strength steels or integration of additional process steps in the forming process. Put us to the test.
SCHULER online Would you like to find out more about our selections? Further information is available on the Internet at www.schulergroup.com. You can also follow us on Facebook at www.facebook.com/schulergroup or on Youtube at http://bit.ly/1gQpND8. There you will find interesting news and worthwhile information.
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TABLE OF CONTENTS
Blanking lines / The entire world of metal forming
AT A GLANCE
Blanking lines
Blanking lines from Schuler offer the complete process
BLANKING LINE WITH PRESS
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BLANKING LINE WITH CROSS-CUT SHEAR
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BLANKING LINE WITH LASER CELL
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sequence – from the coil through the blank stack – from a single source. You work with the latest safety and control concepts. Their modular structure permits solutions that are individually tailored to the user. All the components of the line have been tested in practical operations, are precisely adapted to one another and guarantee the highest levels of availability and reliability. Expansions for processing aluminum and high-strength steels can be easily retrofitted. And it does not matter where the Schuler line will be used – our services are available worldwide.
SCHULER online Would you like to find out more about our blanking lines? You can find our complete product range at www.schulergroup.com/automotive. There, you will find extensive information about our system solutions for large-scale mass production.
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TABLE OF CONTENTS
Blanking lines
Individual solutions, flexible applications
Maximum productivity with ServoDirect presses In addition to the use of conventional presses (mechanical or hydraulic), lines for manufacturing shaped blanks are preferably equipped with servo presses nowadays. ServoDirect technology from Schuler enables movement sequences of the press to be adapted individually to the different blanking dies. This increases productivity and the service lives of dies significantly. Also, lines with this technology are configured for processing an extremely wide range of materials such as aluminum or high-strength steels. Material with a sensitive surface can also be processed carefully, using a press blanking line with the highest productivity. All upstream and downstream automation components, such as the roll feed unit driven directly by servomotors or the flexible Stop2Drop stacker, support the impressive Blanking line with servo press.
press performance and ensure powerful dynamic properties in blanking. A high level of automation ensures quick production changes and a smooth production process.
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Blanking lines / The entire world of metal forming
Blanking line with cross-cut shear.
Blanking line with laser cell.
Blanking with cross-cut shear – the solution
This means there is no need, whatsoever, to invest in dies,
for straightforward blank shapes
die maintenance and die warehousing. The compact design
Schuler offers blanking lines equipped with cross-cut
of the line means it can be used even when space is
shears for manufacturing blanks with a rectangular,
limited and overhead heights are low. With their innovative
parallelogram or curved shape. If the manufacturing
DynamicFlow technology, they offer the most flexible
process is restricted to straightforward blank shapes, then
possible production conditions with comparatively low
cross-cut shears represent the ideal solution – both with
investment costs. The laser cutting line processes an
regard to purchase costs and their productivity. Optionally,
extremely wide range of materials such as aluminum or
the shears can be equipped with an automatic die change.
high-strength steels, and guarantees high productivity even with skin panels that have sensitive surfaces.
Laser cutting: Flexible production, compact line design Blanking lines with lasers are particularly suitable for production sequences with frequent product changes as well, because no tooling is used for laser cutting.
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Blanking lines
Blanking line with press
Blank shapes when using a press with die (max. stroke rate 105 spm).
Output rate of blanking line with servo press Feed length [mm]
300
500
750
1,000
1,500
2,000
2,500
3,000
3,500
4,000
Servo press basic version [strokes / min]
75
71
64
59
51
42
35
30
28
28
Servo press with more powerful motor [strokes / min]
91
79
70
64
51
42
35
30
28
28
Advantages Ideal for producing shaped blanks
Reducing die wear with ServoDirect technology
High output performance
Proven technology
High level of automation
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Blanking lines / The entire world of metal forming
Blanking lines
Blanking line with cross-cut shear
Blank shapes when using a cross-cut shear (max. stroke rate 120 spm).
Output rate of blanking line with 4-column cross-cut shear Feed length [mm]
300
500
750
1,000
1,500
2,000
2,500
3,000
3,500
4,000
Cross-cut shear [strokes / min]
100
80
66
57
47
41
35
30
28
28
Advantages Ideal for producing blanks with a rectangular, parallelogram or curved shape Attractive price / performance ratio
High output performance High level of automation Proven technology
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Blanking lines
Blanking line with laser cell
Blank shapes when using laser cutting heads.
Output rate of a blanking line with laser The productivity of a laser line must always be seen in the context of sheet metal thickness, blank contour and laser power. We would be happy to calculate the possible productivity for you on the basis of your product data.
Advantages Suitable for all blank shapes
Reduced material costs
No costs for dies and die warehousing
High energy efficiency
Fast product change, delivering a high level of availability
Reduced investment volume
Adaptation of blank contours after production startup
Space-saving line design
Simultaneous production of different blank shapes
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Blanking lines / The entire world of metal forming
Blanking line with ServoDirect technology
In practice Customer: Automotive supplier, People's Republic of China
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1. Decoiler 2. Coil infeed 3. Crop shear 4. Coil washing machine 5. Leveling machine 6. Loop pit
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10
7. Roll feed unit 8. Telescopic roller train with left-over coil feed 9. Blanking press with ServoDirect technology 10. Cutting die
The requirements:
The solution:
Delivery of a blanking line for
Fully automated blanking line with
11. Telescopic conveyor 12. Vacuum blower for stacking aluminum blanks 13. Blank stacker 14. Stack cart 15. Hydraulic unit
Leveling machine with crowning function with 2 cassettes (17 rolls)
producing shaped blanks with
blanking press in ServoDirect
Loop equipment
the shortest downtimes during a
technology.
Roll feed unit with weld detection
coil change.
Coil loading cart for two coils
Blanking press with 8,000
Cutting steel, aluminum and
Moving decoiler for 35 tons
kilonewtons in ServoDirect
high-strength steels up to
Threading unit with dirt and
technology
1200 newtons / square millimeter
clean rolls
Stacker in Fly2Drop and Stop2Drop
Coil width: 2,150 millimeters
Cropping station
stacker technology (energy-efficient
Coil thickness: 0.5 to 2.5 millimeters
Coil washing machine
vacuum generation by blower)
Coil weight: 35 tonnes
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TABLE OF CONTENTS
Hydraulic single presses / The entire world of metal forming
AT A GLANCE
Hydraulic individual presses
You've got to be flexible. We've got the machines to help.
Hydraulic individual presses
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Presses for the non-automotive industry
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Hydraulic transfer presses
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Hydraulic press systems from Schuler are extraordinarily versatile and make it possible for you to achieve efficient series production of a wide range of components – from the blank through the finished part. At the same time, innovative hydraulic solutions ensure high output levels, production reliability and the best quality. Whether in classic metal forming, die tryout, die hardening, tubular hydroforming, precision blanking or processing fiber-reinforced plastics: hydraulic presses from Schuler can cope with any challenge – round the clock, seven days a week.
SCHULER online Would you like to find out more about our hydraulic presses? You can find our complete selection at www.schulergroup.com/hydraulic_press. In addition, you can download the »Hydraulic press systems. For the best component quality in the stamping plant« brochure as a PDF file.
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TABLE OF CONTENTS
Hydraulic individual presses
Flexible application with high production reliability Economical, flexible and for reliable production Because of their versatility, hydraulic presses offer a wide range of applications in the stamping plant. They can be used as a single press, automated press line, transfer press or, with slight modifications, as a tryout press. In combination with a coil line, destacker or tri-axis transfer, this creates turnkey system solutions for economical parts production. These have a modular structure and offer users a wide range of expansion options. Equipped with a hydraulic bed cushion, impact shock dampening, slide parallelism control and cylinder mode switching, hydraulic presses provide all the prerequisites for efficient production in the component supplier's stamping plant. A data analysis system assists the press operator in straightforward fault diagnosis of the entire Hydraulic presses offer flexible applications.
system, at the same time as increasing productivity and optimizing the process.
Advantages They can be used as a single press, in press lines or as a transfer press Production alternative for a wide range of parts Reduction in unit costs by dynamic cylinder mode switching Simple operation by slide comfort control
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High process quality through impact shock dampening and a hydraulic bed cushion Parallelism control increases parts quality and reduces die wear Precise eight-way slide guidance
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Hydraulic single presses / The entire world of metal forming
Hydraulic press with a press force of 4000 kilonewtons
1. Press cylinder 2. Adjustable eight-way precision slide guidance with solid guide
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3. Hydraulic drawing cushion 4. Hydraulically operated slide locking in upper end position
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as per UVV (safety codes and regulations)
1
5. AC drive motors designed to suit application
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4
6. High-performance axial piston pumps with electronic pump control
2
7. Torsion-resistant press frame 8. Slide / piston connection 9. Slide / limitation / impact shock dampening
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10. Impact shock dampening cylinder
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Model overview HYDRAULIC PRESSES 1,600 to 16,000 kilonewtons Press force [kN]
1,600
2,500
3,150
4,000
1,300 1,600 2,000
1,300 1,600 2,000
1,300 1,600 2,000
1,300 1,600 2,000
1,600 2,000 2,500
1,600 2,000 2,500
1,600 2,000 2,500 3,000
1,600 2,000 2,500 3,000
1,600 2,000 2,500 3,000
1,600 2,000 2,500 3,000
1,600 2,000 2,500 3,000
2,000 2,500 3,000
2,500 3,000
2,500 3,000
2,500
2,500 3,000
2,500 3,000
2,500 3,000
2,500 3,000
2,500 3,000
2,500 3,000
2,500 3,000
Bed length [mm] 1,000 1,300
1,600
5,000
6,300
8,000
10,000
12,500
16,000
Bed width
Daylight [mm] Standard
Option
700
1,000
850
1,300
1,100
1,600
On request, hydraulic presses are available with alternative bed sizes and press forces up to 100,000 kN. 17
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Hydraulic drawing press for manufacturing side sill plates
In practice Customer: Automotive components supplier, Czech Republic
Hydraulic press for producing side sill plates and roof bows.
Maximum output rate of the line: 12 strokes / minute.
Semi-automatic die change in 15 minutes.
The requirements: Delivery of a production line for finish-processing of preformed side sill plates and roof bows. Perform pick-up Component transfer through the press Hole punching and forming of specified contours The solution: Hydraulic blanking and coining press with tri-axis gripper transfer, blanking and forming dies. Press force: 2,500 kilonewtons Bed size: 2,500 × 1,300 millimeters Slide parallelism control with screw adjustment Roll-formed component pick-up by robot Part transfer into the press and through the die stations Semi-automatic die change in 15 minutes Maximum output rate: 12 strokes / minute
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Hydraulic single presses / The entire world of metal forming
Hydraulic individual presses
Presses for the non-automotive industry
Hydraulic presses for the non-automotive industry Hydraulic presses represent an efficient alternative for a wide range of production tasks in the domestic appliance industry as well as for manufacturers of components made from stainless steel. Both single presses and automated production systems increase users' competitiveness. The lines are characterized by high reliability, availability, fast die changes as well as straightforward adaptation to modified production conditions. Pre-engineered press configurations in conjunction with a wide variety of modular automation options and die change techniques permit customer-specific manufacturing solutions. The lines are also noted for their high degree of user-friendliness. Hydraulic presses for producing stainless steel sinks.
Advantages Reliable equipment with high levels of uptime Maximum flexibility Optimum line configuration using proven components
Maintenance-friendly because of easy accessibility of all components High part quality due to sturdy design Process analyses with integrated data analysis system
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Hydraulic press for manufacturing heat exchanger plates
In practice Customer: Manufacturer of heat exchanger plates, USA
Hydraulic coining press. Press force: 25,000 kN.
Fully automatic production system for manufacturing heat exchanger plates.
Heat exchangers of various sizes.
The requirements:
The solution:
THE PRODUCTION SYSTEM:
High requirements apply to fully
The fully automated production
Blanking system with coil line
automated forming of heat exchanger
system has at its heart the hydraulic
Lifting bar transfer system for
plates: high stamping forces, many
coining press with a multi-cylinder
different plate geometries, close
system in short-stroke technology.
Loading and unloading feeder
tolerances in stamping depth,
The system permits flexible
Foil winding units
production process reliability and
adaptation of press force ranges to
Fully automated die change systems
high equipment availability.
the different geometries and
Master controller
process technology sequences.
Presses for edge trimming and
transporting parts in the press
hole-punching for fluid outlets
Advantages Flexible adjustment of the pressure circuits, adapted to various plate shapes Optimal press force distribution and material flow control thanks to pre-selection of individual pressure circuits and adjustment of individual cylinder pressures
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Bowing or shimming of the dies no longer required Deflection between bed and slide reduced to a minimum
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Hydraulic single presses / The entire world of metal forming
Hydraulic individual presses
Hydraulic transfer presses
Hydraulic transfer press. Press force: 25,000 kN.
Feeder loading station with blank singling.
Efficiency, step by step Hydraulic transfer presses permit part production on
the capacity range for these presses is 5,000 to
multi-station transfer dies. High throughput rates can
30,000 kilonewtons. The active electrohydraulic slide
be achieved due to hydraulic solutions such as the
parallelism control and hydraulic impact shock
Schuler ring valve technology and dynamic cylinder mode
dampening ensure superior part quality and reliability
switching. In single-slide or multi-slide design (with
in the forming process. Other auxiliary functions
options for one or more bed and / or slide cushions),
can be directly integrated into the die.
Advantages Easy to adapt to different dies
Production of deep components by counter drawing
Freely programmable slide motion curves
Nominal capacity available over the entire stroke
Programmable pressure dwell in BDC
Simple die startup
High level of availability
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Mechanical single presses / The entire world of metal forming
AT A GLANCE
Mechanical individual presses
Blanking and forming systems from Schuler are used
C-frame presses
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Automatic blanking presses
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Knuckle-joint presses
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Presses with ServoDirect technology
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Presses with TwinServo technology
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Transfer presses
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Multiple-slide transfer presses
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successfully in a very wide range of industries. Sheet metal parts produced flexibly and economically with the best quality, and overcome challenges such as large part quantities, complicated part geometries and processing high-strength materials. The breadth of our product range for economical series production of high-quality components is matched only by the requirements of the various industries. Whether C-frame presses, automatic blanking presses, knuckle-joint presses, servo presses or conventional mechanical transfer / prog-die presses – together, we can find the right solution for your success.
SCHULER online Would you like to find out more about mechanical single presses? You can find our complete selection at www.schulergroup.com/stamping_cutting. In addition, you can download the »At Home in Every Industry. Blanking and Forming Systems from Schuler.« brochure as a PDF file.
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Mechanical individual presses
C-frame presses
For universal application C-frame presses provide small and medium-size companies high product quality at low per unit cost. Innovative solutions for equipment and controls ensure an integrated manufacturing process. The machines are configured for manual loading (CB series) and either manual loading or automatic mode (C series). MODULAR – FLEXIBLE – ERGONOMIC The newly developed C-FLEXline (CFL) series is based on a combination of experience gained from users and more than 70 years of experience in building C-frame presses. The modular structure makes it possible to adapt to changing production conditions at any time – from straightforward manual loading to fully automatic production. The presses are converted quickly and ergonomically, while two different control concepts allow the presses to be adapted to individual
C-FLEXline 630 kN comfort with foot pedal.
customer requirements.
Model overview of C-frame presses Model
CB-250
CB-400 C-400
CFL-630
CFL-1000
CFL-1600
C-2500
Press force [kN]
250
400
630
1,000
1,600
2,500
Drive capacity [kW]
1.5
2.2
4
7.5
18.5
18.5
Stroke rate [spm / ]
150
60 – 140
30 – 120
30 – 90
20 – 70
19 – 57
Adjustable slide stroke [mm]
5 – 75
5 – 100
8 – 120
10 – 130
12 – 180
19 – 250
Slide adjustment [mm]
50
70
100
100
110
130
Bed dimensions [mm]
465 × 360
650 × 480
820 × 590
950 × 660
1,250 × 750
1,400 × 860
Slide dimensions [mm]
220 × 160
370 × 300
470 × 410
540 × 510
850 × 630
1,000 × 700
Shut height* [mm]
270
240
320
370
440
470
Throat [mm]
185
220
280
330
370
430
Weight with normal equipment [kg]
2,000
3,000
5,000
7,000
14,000
28,000
* Maximum stroke down, slide adjustment up, without clamping plate. 24
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Mechanical single presses / The entire world of metal forming
Mechanical individual presses
Automatic blanking presses
Motion characteristics
max.
Stroke [mm]
Time [s]
0
Sinusoidal profile Modified sequence (servo drive) Automatic blanking presses: The optimum solution for straightforward components.
Wide range of parts – high output
The blanking presses are also available up to 2,000
Blanking presses (MC series) are standard machines with
kilonewtons with servo drive as well (MSC series). Eight
extensive basic equipment for blanking classic sheet metal
predefined slide speed profiles enable optimum adaptation
components from the coil. In the range from 1,250 to 5,000
to the components to be produced. In combination with
kilonewtons, they represent an optimally-priced solution
an integrated high-performance transfer system, it is
for manufacturing components with high output rate.
also possible to manufacture stampings with complex geometry directly from the die.
Advantages Little bowing due to rigid welded construction
Optional servo drive permits optimized speed profiles
Long slideways ideally absorb off-center forces
for higher output with the same component quality
Two transverse shafts compensate for rotational forces without additional masses Low-noise drive with helical gearing
and longer die service lives Quick conversion to new die Hydraulic overload protection protects the machine and the die
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BLANKING PRESS
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1
1. Flywheel with pneumatic clutch
2
2. Torsion-resistant press frame
3
3. Press drive by helical gearing 4. Bolt fittings for high pull-back forces 5. Lubricated, re-adjustable eight-way precision guiding
8
4
7
5
6. Press bed openings provided for scrap removal 7. Hydraulic overload protection 8. Slide counterbalance 9. Intermediate gear for diametrically opposed running of eccentric gears
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Model overview of BLANKING PRESSES (MC) and blanking presses with servo drive (MSC) Model
MC-1250 MSC-1250
MC-2000 MSC-2000
MC-3000
MC-4000
MC-5000
Press force [kN]
1,250
2,000
3,000
4,000
5,000
1,300
1,400
Bed length [mm] 1,400
Bed width 1,000
1,800
1,100
2,200
1,300
3,000
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Shut height [mm]
450
550
650
750
800
Slide adjustment [mm]
150
150
150
200
250
Adjustable slide stroke [mm]
20 – 180
20 – 220
40 – 315
40 – 315
40 – 315
Stroke rate MC [spm]
30 – 150
30 – 130
25 – 100
20 – 80
20 – 70
Stroke rate MSC [spm]
130
100
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Mechanical single presses / The entire world of metal forming
High-speed blanking press The two-rod high-speed blanking press (MCF series) is designed for producing components with output rates of up to 300 strokes / minute. The slide guidance system with preloaded, play-free roller bearing units also guarantees the necessary precision in the process: the best prerequisite for series production of small components with tight die clearances. In these lines and processes, perfect synchronization between automation and the blanking press is of great importance. Users can fully tap the output potential of the new press generation in practical operation. The advantages: Fast and reliable press type Output rate up to 300 strokes / minute Stress-relief annealed frame Long die service lives
MCF twin-rod high-speed blanking press.
Longitudinal shaft machines with rotary mechanical counterbalance Linear roller bearings Planetary gear unit ensures high available power, even at low speeds Fully automatic stroke and slide adjustment reduces die change times Infinitely variable overload protection for die and machine
Model overview of high-speed BLANKING PRESSES (MCF) Model
MCF-630
MCF-800
MCF-1000
MCF-1250
MCF-1600
MCF-2000
Press force [kN]
630
800
1,000
1,250
1,600
2,000
700
700 1,000
1,000
500
500
Bed length [mm] 1,000
Bed width
1,300
800
800
400
400
1,600 Shut height [mm]
350
350
Slide adjustment [mm]
70
70
100
100
100
100
Adjustable slide stroke [mm]
12 – 80
12 – 100
10 – 100
10 – 120
10 – 120
10 – 130
Stroke rate [spm]
30 – 300
30 – 300
30 – 280
30 – 280
30 – 260
30 – 260
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Mechanical individual presses
Knuckle-joint presses
Knuckle-joint press with servo drive. Press force: 8,000 kN.
Control panel of the overall machine.
Precise in operation The very rigid press concept and the slide movement that
be combined with one another. The optional use of
is characteristic of knuckle-joint presses guarantee that
ServoDirect technology also ensures extra flexibility and
ready-to-install precision parts can be manufactured
productivity. The new PSK and PSK PLUS series are
economically. Each machine permits efficient blanking,
the perfect solution for components with increased
drawing, embossing, punching and calibrating in one
requirements for precision and smooth cutting proportion.
operating sequence, while the various stations can also Advantages Optimized slide motion by modified knuckle-joint drive and maximum production flexibility with user-programmable
High system rigidity for close component tolerances and reduced cutting impact
stroke heights and motion sequences in knuckle-joint
Excellently suited for processing high-strength steels
presses with servo drive
Reliable repeat accuracies, even with fluctuating
Drawing, bending, cleaning, blanking and calibrating operations in one press cycle
material thicknesses and strengths Shorter die startup times by precision setup using hand wheel
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Mechanical single presses / The entire world of metal forming
Model overview of knuckle-joint presses (TMK) Press force [kN]
2,000
2,500
3,150
1,500
1,000
1,000
2,000
1,000
1,000
1,100
1,100
2,500
1,000
1,000
1,100 1,100
Bed length [mm]
4,000
5,000
6,300
8,000
10,000
15,000
1,100
1,200
1,400
1,100
1,200 1,200
1,400
1,500
1,500
1,500
1,400
1,500
1,500
1,500
Bed width
3,000 3,660 Shut height [mm] Stroke down
400
500
600
700
700
800
800
800
800
Adjustment up
500
600
700
800
800
900
900
1,100
1,100
Slide adjustment [mm]
150
150
150
150
150
200
200
200
200
with stroke adjustment
40 – 160
40 – 160
60 – 200
60 – 200
60 – 200
80 – 250
80 – 250
with fixed stroke
160
160
200
200
250
250
250
300
300
with stroke adjustment
20 – 140
20 – 140
20 – 120
20 – 120
20 – 90
20 – 90
20 – 80
with fixed stroke
20 – 110
20 – 110
20 – 95
20 – 95
20 – 75
20 – 75
20 – 70
20 – 65
20 – 50
Slide stroke [mm]
Stroke rate [spm / ]
Model overview of knuckle-joint presses with servo drive (MSK) Press force [kN]
2,500
4,000
Bed length [mm] 2,000
8,000
10,000
15,000
1,300
1,300
1,300
1,300
3 – 80
3 – 70
3 – 60
3 – 60
Bed width 1,000
2,500
1,000
3,500 Stroke rate [spm / ]
6,300
3 – 160
3 – 120
All information for systems with two-conrod design. Stroke rate depending on programmed stroke height and kinematics.
Model overview of knuckle-joint presses with servo drive for precision blanking and forming processes (PSK) Model
PSK / PSK Plus2-250
PSK / PSK Plus2-400
PSK / PSK Plus2-630
PSK / PSK Plus2-800
PSK / PSK Plus2-1000
PSK / PSK Plus2-1500
Press force [kN]
2,500
4,000
6,300
8,000
10,000
15,000
Stroke height in full stroke [mm]
160
200
300
300
300
300
Stroke height in oscillating mode [mm]
40–120
50–150
75–225
75–225
75–225
75–225
Stroke rate* [spm/ ]
3–160
3–140
3–100
3–80
3–70
3–60
2,000
1,000
1,100
2,500
1,000
Bed length [mm]
Bed width
3,000
1,100
1,300
1,300
1,100
1,300
1,300
1,300
1,300
3,500
1,300
1,300
1,300
1,300
Shut height [mm]
600
700
800
800
900
900
Slide adjustment [mm]
150
150
200
200
200
200
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TABLE OF CONTENTS
Mechanical individual presses
Presses with ServoDirect technology
Operating panel of a servo press.
Production with optimally matched system components.
Success can be programmed Presses with ServoDirect technology open completely new
automatic forming systems are created for a broad range
perspectives: maximum flexibility in production,
of parts. The presses are driven directly by torque motors
economical production of complex parts geometries and
which permit highly dynamic forming processes thanks to
a high level of productivity with optimum parts quality. In
their high torque. The lack of a flywheel and clutch / brake
combination with highly dynamic Schuler roll feed units,
combination makes the presses flexible, energy efficient
coil lines, destackers or tri-axis transfer systems, fully
and cuts down the maintenance required.
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TABLE OF CONTENTS
Mechanical single presses / The entire world of metal forming
FLEXIBILITY AND EFFICIENCY
Stroke [mm] max.
max.
Stroke [mm]
Reduction in cycle time
0
Time [s]
Motion profile of conventionally driven eccentric press Motion profile of the servo press with optimized performance Operation in oscillating stroke
Time [s]
0
Oscillating mode, small stroke Oscillating mode with rest position Pass-through mode
Individual programming of the slide motion reduces the cycle time while keeping the forming speed constant.
ServoDirect technology allows the slide motion to be programmed individually.
Programmable slide motion curves
Oscillating stroke mode
The use of highly dynamic torque motors permits
Oscillating stroke mode permits user-programmable slide
straightforward and rapid programming of different
stroke heights. The reversing movement of the torque
movement profiles in one press cycle. This means the
motor means that the eccentric drive of the slide has an
slide kinematics can be quickly and easily adapted to
oscillating motion and alternates between forward in one
the process parameters of the die and the automation
stroke and backward in the next stroke. This significantly
system, and optimized for a high stroke rate.
improves cycle count and energy efficiency.
Advantages Significant increase in productivity compared to conventionally driven mechanical presses Maximum production flexibility due to user-programmable stroke heights and motion sequences Increased parts quality and die lives due to motion sequences optimally adapted to the particular forming requirements Greatest availability for production mode
Short delivery times and optimized spare part management due to standardized modules Shorter die tryout times because of setup and tryout functions with hand wheel Lower energy costs due to efficient drive solution Easier maintenance compared to conventionally driven mechanical presses, because there are fewer mechanical components.
Best suited for processing high-strength steels
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TABLE OF CONTENTS
Servo press in monoblock design. Press force: 2,500 kN.
Servo presses in monoblock design. Press force: 4,000 kN each.
Servo press in monoblock design. Press force: 6,300 kN.
Model overview of servo presses in monoblock design Modell Press force [kN]
MSD 250
MSD 400
MSD 630
MSD 800
2,500
4,000
6,300
8,000
Bed length [mm] 2,000
Bed width 1,100
2,500
1,100
3,050
1,400
4,000
1,800
1,800
Shut height [mm]
550
600
700
1,000
1,000
Slide stroke [mm]
32 – 160
40 – 200
60 – 300
80 – 400
80 – 400
Slide adjustment [mm]
150
200
250
300
300
Stroke rate [rpm]*
3 – 160
3 – 140
3 – 90
3 – 60
3 – 60
All information for systems with two-point connecting rod design. Subject to technical modification. *Stroke rate depending on programmed stroke height and kinematics.
Energy management
Reliable components
Tryout
Energy accumulators can be used as
The monoblock press body is
Starting up new dies demands the
an option in order to reduce the
implemented as a stress-free
greatest flexibility. The setup speed
connected load. This means energy is
annealed welded structure. The
can be varied by a hand wheel. The
returned to the energy accumulator
eccentric gears have a double
slide can be stopped in any position
during the press cycle in the
herringbone profile to provide axial
and the direction of movement can be
generative braking phase. This stored
guidance and to reduce noise. The
reversed if required. The quick-lift
energy is available during the
slide roller guide is preloaded to
function makes it possible to move the
subsequent motor acceleration phase,
eliminate play. This results in
slide to the maximum top reversing
without imposing any additional load
components that guarantee high
point at any moment during the setup
on the electrical system.
availability of the machine.
procedure.
32
TABLE OF CONTENTS
Mechanical single presses / The entire world of metal forming
Servo press in monoblock design with automation
6
7
1
2
3
4
5
8
9
LEGEND 1. Coil feed line 2. Decoiler 3. Leveling machine 4. Loop pit
5. Roll feed unit 6. Servo press in monoblock design 7. Electronic, modular tri-axis transfer
8. Operator panel 9. Energy accumulator
33
TABLE OF CONTENTS
Highest line availability The "Kurvengenerator" (curve generator) software developed by Schuler allows optimum tuning of slide motion properties and automation parameters – for the highest process reliability. The design of all components has been optimized using FEM calculation methods. The press bodies are built as welded structures and annealed to reduce stress. Reduced startup and setup times Wide range of tryout functions for the production press using hand wheel function: Die closing movement with variable setup speed Intermittent movement with reversing movement when required Spotting function with selectable die force Quick-lift function for rapid die opening Servo press in tie rod design. Press force: 11,000 kN.
Different die change systems such as tandem change cart or an extendable bed plate achieve short changeover times.
Model overview of servo presses with tie rod design Model
TSD 630 TSC 630
TSD 800 TSD 1000 TSC 800 TSC 1000
Press force [kN]
6,300
8,000
1,600
1,800
10,000
TSD 1100 TSC 1100
TSD 1250 TSC 1250
11,000
12,500
Bed length [mm] 4,000
TSD 1600 TSD 2000 TSD 2500 TSD 3200 TSC 1600 TSC 2000 TSC 2500 TSC 3200 16,000
20,000
25,000
32,000
2,500*
2,500*
2,500*
Bed width
4,600
1,800 / 2,200*
1,800
5,000
2,200*
5,100
2,200
1,800 / 2,200*
1,800
1,800 / 2,200*
1,800 / 2,500*
6,000
2,500*
6,100 7,000
2,500*
2,500*
2,500*
Shut height [mm]
900
1,100 / 1,100
1,100
1,200
1,100 / 1,200
1,100 / 1,300
1,400
1,400
1,400
Slide stroke [mm]
100 – 350
120 – 450 / 120 – 500
120 – 450
150 – 600
120 – 450 / 150 – 600
150 – 450 / 200 – 600
200 – 700
230– 700
230 – 700
Slide adjustment [mm]
300
300 / 300
300
300
300 / 300
300 / 300
300
300
300
Stroke rate** [rpm] TSD TSC
3 – 70
3 – 60 / 3 – 50 3 – 50
3 – 50
3 – 45 3 – 36
3 – 45 / 3 – 40 3 – 38 / 3 – 34
3 – 40 / 3 – 363 – 32
3 – 34
3 – 30
3 – 30
34
All information for systems with two-point connecting rod design. Subject to technical modification. *Four-point connecting rod design. **Stroke rate depending on programmed stroke height and kinematics.
TABLE OF CONTENTS
Mechanical single presses / The entire world of metal forming
Servo press in tie rod design with automation
8
9
10
1
2
3
4
5
6
7
11
13
12
LEGEND 1. Material feed (operation either with coil feed line or destacker) 2. Decoiler 3. Leveling machine 4. Destacker, two destacker carts including scissor-lift table and double-blank depositing station
5. Roll feed unit 6. Coil or blank lubricating unit 7. Transfer and centering station 8. Servo press in tie rod design 9. Electronic, modular tri-axis transfer
10. Combined sequential or transfer die 11. Exit conveyor 12. Hydraulic, modular drawing cushion 13. Scrap disposal
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TABLE OF CONTENTS
Servo presses
In practice Blanking trials and process integration
Seat shell.
Component with welded nut.
Cylinder head gasket.
Integration of follow-on
allow completely new working
sequences, as well as by providing
processes
methods. Processes such as welding
rest times. The results are
Frequently, component production
or laser cutting can be integrated
economical production of complex
involves several production steps
directly into the press cycle in a
parts geometries and highest output
which – performed one after another
reliable process and with high output
rates with maximum quality. For
– take up time and productivity. Highly
rates because of the opportunities for
extra efficiency.
dynamic servomotors from Schuler
user-programmable time / distance
36
Formed part
Mode
Component-specific press force [kN]
Depth of draw [mm]
Max. stroke rate Conventional
Max. stroke rate Servo
Increase
Flange
Progressive
1,200
30
30
56
+ 87 %
Gas generator holder
Progressive
1,300
60
25
40
+ 60 %
Holder
Progressive
2,000
40
30
60
+ 100 %
Cage
Progressive
2,400
50
30
50
+ 67 %
Cross plate
Progressive
4,000
90
23
33
+ 43 %
Cover
Progressive
6,900
40
15
34
+ 126 %
Center console
Transfer
6,000
190
12
17
+ 42 %
Insert cup
Transfer
6,600
130
8
15
+ 88 %
Support
Transfer
7,190
67
14
30
+ 114 %
Tank filler neck
Transfer
9,650
145
14
18
+ 29 %
Seat shell
Transfer
12,600
130
16
24
+ 50 %
Side panel
Transfer
14,750
80
19
29
+ 53 %
TABLE OF CONTENTS
Mechanical single presses / The entire world of metal forming
Servo presses
In practice Customer: Automotive components supplier, Germany and Austria
Servo press in monoblock design. Press force: 4,000 kN.
Servo press in tie rod design with 16,000 kN press force, coil feed line and destacker combination.
The requirements:
The requirements:
Delivery of a servo press for producing a wide range
Delivery of a servo transfer press – with complete
of parts.
automation for manufacturing structural components in progressive or transfer mode.
The solution: Servo press in monoblock design with a maximum press
The solution:
force of 4000 kilonewtons. Automated with coil line and
Servo press in tie rod design with a press force of
feed unit.
16,000 kilonewtons and Schuler automation components.
Monoblock design
Coil line / destacker combination
Bed surface: 2,500 × 1,100 millimeters
Roll feed unit
Slide stroke 300 millimeters
Electronic, modular tri-axis transfer
Maximum stroke rate in continuous operation:
Conveyor belt
80 strokes / minute
Bed surface: 6,000 × 2,500 millimeters Slide stroke: 600 millimeters Tie rod design
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TABLE OF CONTENTS
Mechanical individual presses
Presses with TwinServo technology
Advanced thinking in servo technology Following the market launch of ServoDirect technology, the next milestone in a success story was set with TwinServo technology. The new press generation is driven by decentralized TwinServo technology, which offers users additional interesting possibilities in sheet metal forming. The performance capabilities of this innovative press technology are impressively demonstrated by Schuler at its UmformCenter Erfurt on a new transfer press. The new press system produces at a press force of 16,000 kilonewtons and is fully automated with components from Schuler.
TwinServo transfer press at the Schuler UmformCenter Erfurt.
Model overview of TwinServo presses Press force [kN]
10,000
16,000
Bed length [mm] 5,000
20,000
25,000
30,000
35,000
Bed width standard and option* 2,200
6,000
2,200*
2,500* / 2,200*
3,000 / 2,500*
2,500
2,500* / 2,200*
3,000 / 2,500*
3,000* / 2,500*
3,000*
3,000 / 2,500*
3,000 / 2,500*
3,000*
3,000 / 2,500*
3,000
7,000 8,000 Slide stroke [mm]
600
600
600
750
750
750
Slide adjustment [mm]
300
300
300
300
300
300
Press force millimeters before BDT [mm]
6
6
6
6
6
6
Number of connection points
4
4
4
4
4
4
Stroke rate at max. stroke** and constant speed [spm] / rated capacity [kJ]
40 / 400
35 / 500
40 / 900
30 / 1,200
25 / 1,500
25 / 1,500
Oscillating stroke rate 1 / 3 stroke**[spm] / rated capacity [kJ]
50 / 250
50 / 250
60 / 400
40 / 650
35 / 700
30 / 900
* Option. ** Deviations possible depending on the motion curve and force profile. 38
TABLE OF CONTENTS
Mechanical single presses / The entire world of metal forming
Automated transfer press with TwinServo technology
In practice Schuler Forming Center Erfurt
Coil line with decoiler and leveling machine.
Transfer press with TwinServo technology. Press force: 16,000 kN.
Die change by moving bolster.
Schuler UmformCenter
The solution:
Destacker
Erfurt:
Press
Schuler destacker with removal
The first transfer press with
Decentralized TwinServo drive
feeder and shuttle device in
TwinServo technology was installed
Press force: 16,000 kilonewtons
the press
at the UmformCenter Erfurt.
Main motors: 2 × AC servo torque motors 503 kilowatts Four contact points Bed dimensions (L × W):
Transfer Electronic tri-axis rhombus transfer from Schuler
5000 × 2200 millimeters Slide stroke: 600 millimeters
Additional equipment
Slide adjustment:
Two moving bolsters and parts
300 ±0.1 millimeter
outfeed belt
Stroke rate: Controllable 3 – 30 / minute, in oscillating mode
Dimensions
without transfer 3 – 40 / minute
Total length of the machine: 25 meters
Coil feed line Coil line with decoiler, leveling machine, coil-end welding device, PowerFeed roll feed unit and
Press height over floor: 6.50 meters Required foundation depth: 5.30 meters
spraying system, can be used with aluminum
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TABLE OF CONTENTS
Mechanical individual presses
Transfer presses
Individually adjustable forming stations Multi-station presses differ from transfer presses mainly in the ability to adjust individual forming stations. Another difference in multi-station presses is the externally mounted blanking slide for integrated blank production. Multi-station presses are built both as single-slide and multi-slide machines with a press force range from 2500 kilonewtons to 60,000 kilonewtons. Either mechanical or electronic rail transfer systems are used for parts transport. The advantages are high output and high availability, individual station adjustment in each station and, if necessary, the externally mounted blanking slide for integrated blank production.
Mechanical multi-station press.
Multi-station press with externally mounted blanking slide 1. Crown with press drive 2 Press upright
1
3. Drawing slide 2
4. Transfer system 5. Die change cart
6
5 7
40
3
6. Blanking slide
4
7. Drawing cushion
TABLE OF CONTENTS
Mechanical single presses / The entire world of metal forming
Mechanical individual presses
Multiple-slide transfer presses
Multifunctional mass production Multi-slide transfer presses deliver impressive practical performance as a functional unit comprising press, transfer and material feed. The configuration is based on the parts spectrum, die size and forming process. Singleslide, double-slide or triple-slide machines are used, depending on the parts spectrum, which also influences the size and number of dies. Parts are transported by a rail transfer system which can be equipped either with cam-controlled or electronic drive.
Multi-slide transfer press.
Multi-slide transfer press 1
2
1. Destacker
3
2. Transfer press 4
3. Tie rod 4. Crown
5
5. Upright
6
6. Slide 7. Finished part unloading belt 8. Moving bolster 7
9. Damping element 10. Drawing cushion
10
9
8
41
04
42
TABLE OF CONTENTS
TABLE OF CONTENTS
Automation of single presses / The entire world of metal forming
AT A GLANCE
Automation of single presses
Our automation ideally combines the press, automation
Destacker
44
coil feed lines
45
Roll feed unit
48
TRI-axis transfer
50
devices and die, offering impressive precision and process reliability. With automation components from Schuler, you benefit from a greater output rate even when processing high-strength steels or aluminum.
SCHULER online Would you like to find out more about automating single presses? You can find our complete selection at www.schulergroup.com / automation. In addition, you can download the »Performance Along the Line – Automation from Schuler« brochure as a PDF file.
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TABLE OF CONTENTS
Automation of single presses
Destacker
Destacker with transfer system for blank destacking.
In order to automate transfer presses, Schuler not only offers tried-and-tested destackers but also a special solution. This consists of a mobile combination of coil line in short design with a destacker. For the press owner, this solution opens a wide range of options regarding material and flexibility for efficient part production. It represents a flexible solution for blank and coil processing on a single line. The control is compatible with both the press and transfer, and meets all production requirements.
44
Integrated system solution. Destacker and coil line on a servo press. Press force: 16,000 kN.
TABLE OF CONTENTS
Automation of single presses / The entire world of metal forming
Automation of single presses
Coil feed lines
Coil feed lines in short design Our coil feed lines in short design have been specially developed for the requirements of customers in the components industry. They offer process reliability while meeting the highest material requirements. The lines are optimally suited for producing structural components and processing high-strength materials – even in the higher coil thickness range. They are the ideal solution when space is at a premium. Our product range includes coil feed lines in various high-performance basic versions, and is adapted to all press types. The modular concept permits flexible configuration of the lines. With our extensive package of options, you can react to new requirements at any time while keeping control over your investments.
Reference data of the basic versions Coil feed line in short design.
Coil width [mm]
up to 1850
Coil thickness [mm]
up to 12
Coil weight [t]
up to 27
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TABLE OF CONTENTS
Coil feed lines in long design Compact Line product line The Compact Line from Schuler has been specially developed for small coil widths and tonnages. It covers coil widths up to 800 mm and tonnages up to 7.4 tons for requirements with a straightforward level of automation. Power Line product line As an expansion of the Compact Line product line, Power Line coil feed lines are available for large coil widths and tonnages. These Schuler coil feed lines do full justice to the requirements of the automotive and components industry for material feed with the option of a high level of automation for high-speed, prog-die and transfer presses. Coil widths up to 1850 millimeters and coil weights up to 27 tons make it possible to prepare coil material for structural and skin panels as well as blanks. Schuler Power Line.
Technical data of the compact line Compact Line
L-BS 0450
L-BS 0650
M-BS 0800
Coil weight max. [t]
3
5.5
7.4
Coil width min. [mm]
110 [40]
110 [40]
110
Coil width max. [mm]
450
650
800
Coil thickness min. [mm]
0.5
0.5
0.5
Coil thickness max. [mm]
4
4
6
Leveling rolls Ø [mm]
70
70
70
Loop radius [mm]
1,000
1,000
1,300
Technical data of the Power Line Basic versions of coil feed lines in long design Coil data for »Light« weight class POWER LINE
L-BS 0650
L-BS 0800
L-BS 1050
L-BS 1300
L-BS 1600
Coil weight max. [t]
5.5
12
12
14.5
17
Coil width min. [mm] Coil width max. [mm] Coil thickness min. [mm]
650
110 [80] 800
1,050 0.5
Coil thickness max. [mm]
4
Leveling rolls Ø [mm]
53
Loop radius [mm]
46
110 [40]
1,000
1,300
1,600
TABLE OF CONTENTS
Automation of single presses / The entire world of metal forming
Coil data for »Medium« weight class POWER LINE
M-BS 0650
M-BS 0800
M-BS 1050
M-BS 1300
M-BS 1600
M-BS 1850
Coil weight max. [t]
13.5
11.5
12.5
13.5
16
22
120
160
1,050
1,300
Coil width min. [mm]
110
Coil width max. [mm]
650
800
Coil thickness min. [mm]
205 1,600
1.850
4
4.5
0.5
Coil thickness max. [mm]
6
Leveling rolls Ø [mm]
70
Loop radius [mm]
1,300
Coil data for »Heavy« weight class POWER LINE
H-BS 0650
H-BS 0800
H-BS 1050
H-BS 1300
H-BS 1600
Coil weight max. [t]
10
15
15
17
23
800
1,050
1,300
Coil width min. [mm] Coil width max. [mm]
120 650
205
Coil thickness min. [mm] Coil thickness max. [mm] Leveling rolls Ø [mm] Loop radius [mm]
1,600
0.5 8
6 96 1,600
Advantages Flexibility:
Attractive price / performance ratio:
Systems and components available on short notice
Significant cost advantage by modular line configuration
Scalable weight classes > Light > Medium > Heavy
and preconfigured components
Wide range of options can be retrofitted
Energy-efficient by optimum drive configuration
Can be configured for manufacturing structural
Very straightforward maintenance
and skin panels Implementation of customer-specific requirements
User-friendly machine operation:
Rapid retrofitting
Intuitive operating concept
Flexible attachment to existing price systems
Online diagnosis
Variable level of automation: Manual or motor-driven adjustment of the setup axes Visualization
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TABLE OF CONTENTS
Automation of single presses
Roll feed unit
Power Feed roll feed unit The Power Feed roll feed unit shortens the automation time, especially with highly dynamic presses. ServoDirect drives provide greater dynamics and system accuracy, as do the low-play and maintenance-free planetary gear units. In the long term too, this makes it possible to achieve a system accuracy of ±0.05 millimeters. Furthermore, there is an optimally configured roll coating which transfers the high acceleration values to the material. The Schuler Power Feed is divided into different weight classes depending on the mass to be moved: Weight class »L« (Light) with movable mass up to 100 kilograms, »M« (Medium) with movable mass up to 180 kilograms or »H« (Heavy) with movable mass up to 300 kilograms.
Power Feed.
Feed performance diagram, Power Feed (example) Feed time [s]
Stroke rate [spm]
400
0,40
350
0,35
300
0,30
250
0,25
200
0,20
150
0,15
100
0,10
50
0,05
0
0
100
Feed length [mm]
48
200
300
400
500
600
0,00
Feed time 240,0° 180,0° 120,0° 60,0°
TABLE OF CONTENTS
Automation of single presses / The entire world of metal forming
Model variants COIL DATA POWER FEED
L-BP 0300
L-BP 0450
L-BP 0650
L-BP 0800
L-BP 1050
L-BP 1300
L-BP 1600
Coil width min. [mm]
40
40
40
40
40
80
80
Coil width max. [mm]
300
450
650
800
1,050
1,300
1,600
Coil thickness min. [mm]
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Coil thickness max. [mm]
4.0
4.0
4.0
4.0
4.0
4.0
4.0
Coil cross section max. [mm]
750
1,125
1,300
1,600
2,100
2,600
3,200
Loop radius [mm]
1,000
1,000
1,000
1,000
1,000
1,000
1,000
POWER FEED
M-BP 0300
M-BP 0450
M-BP 0650
M-BP 0800
M-BP 1050
M-BP 1300
M-BP 1600
M-BP 1850
Coil width min. [mm]
40
40
40
40
40
80
80
80
Coil width max. [mm]
300
450
650
800
1,050
1,300
1,600
1,850
Coil thickness min. [mm]
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
Coil thickness max. [mm]
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6,0
Coil cross section max. [mm]
1,350
2,025
2,600
2,800
3,150
3,900
4,800
7,200
Loop radius [mm]
1,300
1,300
1,300
1,300
1,300
1,300
1,300
1,300
POWER FEED
H-BP 0650
H-BP 0800
H-BP 1050
H-BP 1300
H-BP 1600
Coil width min. [mm]
40
40
40
80
80
Coil width max. [mm]
650
800
1,050
1,300
1,600
Coil thickness min. [mm]
0.5
0.5
0.5
0.5
0.5
Coil thickness max. [mm]
8.0
8.0
8.0
8.0
8.0
Coil cross section max. [mm]
3,250
4,000
5,250
6,500
6,400
Loop radius [mm]
1,600
1,600
1,600
1,600
1,600
Advantages Connection to all press types
Scalable in weight class and performance
Ideally usable within highly dynamic processes
Available on short notice
ServoDirect drive
Low maintenance requirement
System accuracy of ±0.05 millimeters
Can be retrofitted at any time
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TABLE OF CONTENTS
Automation of single presses
Tri-axis transfer systems
Pro Trans With its three motor versions »L« (Light), »M« (Medium) and »H« (Heavy), Schuler Pro Trans covers low, medium and high part weights and stroke rates. The heavy version has twice the performance capability of the light version, while the medium variant is situated in between. All the transfers owe their significantly improved output performance to having motor systems with direct advance drive, featuring highly dynamic servo drives. Overall, the Schuler Pro Trans has a modular principle: The three defined standard models »AT1«, »AT2« and »AT3« can quickly and easily be adapted to changed requirements. Schuler offers a wide selection of options for this. Power Trans Schuler offers a high-end transfer solution for highperformance presses in the form of Schuler Power Trans Schuler Pro Trans transfer.
and the »S« (Speed) motor system, the use of which permits productivity to be increased even further and by a
The new modular transfer generation is a high-performance
significant amount. For example, the output rate with
addition to sheet metal forming presses. Designed with
Power Trans is up to 30 % higher than with Pro Trans motor
three sizes, the transfer system covers a wide range of
systems. This additional performance is achieved in
applications. In all transfer solutions, active vibration
particular by using newly developed carbon rails with
damping AVD also guarantees reliable parts transport
aluminum profile functions combined with the ServoDirect
with the highest level of dynamic properties and at full
drive. The rails are very light and rigid, which means the
load.
vibration levels are extremely low. As a result, they are ideal for use in highly dynamic production processes.
Advantages Can be retrofitted regardless of the press
Low tendency for vibration
Optimally adaptable to different applications
Short changeover times
Simple and cost-effective performance increase
Large clearances for attaching components for material
High output performance High rigidity in the overall system
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feed and material unloading Left-over strip processing regardless of material
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Intra Trans The Schuler Intra Trans can be equipped with all motor variants from »L« (Light) to »S« (Speed), which means it is suitable for use in presses ranging from conventional to high-performance. In Intra Trans, the transfer rails do not operate through the press window, but are installed between the press uprights. Parts feed in the working
Automation of single presses / The entire world of metal forming
Overview of the sizes Size
Support width [mm]
Press window / drive unit width [mm]
AT1
3,000
up to 1,600
AT2
6,000
up to 2,500
AT3
10,000
up to 5500
direction is performed by movable slides mounted on the transfer rails, with servo drives integrated in the rail. Each
Modular system
carriage of the Intra Trans can be moved individually so the
All models in the Pro Trans, Power Trans & Intra Trans
central joining of parts or even different distances between
series have gripper rail drive units that can be attached in
stations are possible. Using this compact transfer makes
the press (1), between the press uprights (2) or on the
it possible to manufacture larger parts with the same
outside of the press uprights (3). Furthermore, they can be
transfer press. The new transfer solution is also a genuine
installed above (hanging) or below (standing) the transport
alternative to progressive die manufacturing. Conventional
level, resulting in the highest level of flexibility both in
transfers require a larger press for the same maximum
project planning and for retrofitting to existing presses.
part size but the compact design of the Intra Trans means it needs only the same space as the progressive die. The transfer exploits its full benefit: less material is consumed, because the parts are transported by the slides and not by the coil material itself. Additional material is required in combined sequential production, and the material has to be cut off the finished pressed part as scrap. Intra Trans is ideal for retrofitting to existing combined sequential presses as a means of reducing unit costs. Access to the
Slide
die and the die change are possible without restrictions as before, and as far as the operator is concerned there is no difference from the Schuler transfers in the Pro Trans and Power Trans series.
3
2
2
3
Gripper rail drive units
Gripper rail drive units 3
2
1
Moving bolster
1
2
3
Attachment variants of the transfer drive housings of the Schuler transfer system on the press upright.
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05
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Press lines / The entire world of metal forming
AT A GLANCE
Press lines
The future starts with Schuler: with high-quality
Hydraulic press lines
54
Hybrid press lines
56
Mechanical high-speed press lines
57
Servo press lines
59
implementation and the technology of tomorrow, we are taking measures today to ensure the greatest possible productivity in mass production for the automotive industry. Our results satisfy the most exacting requirements and win over our customers worldwide. Flexibility and quality are what we stand for. Our innovations are unusual and practical. we create change for the market, time and time again. Groundbreaking new developments – such as ServoDirect technology, press automation with the crossbar feeder or crossbar robot – ensure the best component quality, high availability and output.
SCHULER online Would you like to find out more about our automotive press technology? You can find our complete selection at www.schulergroup.com/automotive. In addition, the highlight on the page provides direct information about the important aspect of »High-Speed in the Stamping Plant«.
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Press lines
Hydraulic press lines
Fully automated hydraulic press line.
Loading station with robot automation.
Reliable, flexible and economical Hydraulic press lines are mainly used to manufacture a
conventional robots or crossbar robots developed by
wide variety of parts in small to medium batch sizes.
Schuler. The control and graphic display for hydraulic
Depending on the forming operations, the lines consist of
press lines offer the operator uniform, user-friendly
four to six single presses. The production process is fully
operation, efficient fault diagnostics and the management
automated from the blank to the finished component.
of all process and die data for all presses and automation
Depending on requirements, automation is provided by
systems.
Advantages Flexibility in the forming process
Precise slide guiding and rigid press frame
Ease of maintenance and installation thanks to block
Uniform control concept
hydraulics Dynamic cylinder mode switching and ring valve technology increase production rates Automation for tooling and dies to ensure fast changeovers
54
User-friendly operation and efficient fault diagnostics Fast startup of new die sets
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Press lines / The entire world of metal forming
HYDRAULIC PRESS LINES
In practice Customer: TRUCK MANUFACTURER, FRANCE
Existing and newly-developed dies will be used.
Automation with crossbar robot, one destacker and two outfeed belts.
The requirements:
The solution:
When the Euro-6 exhaust standard comes into force on
Hydraulic lead press with 20,000 kilonewtons press force
January 1, 2014, permitted nitrous oxide emissions from
Three hydraulic follow-up presses, each with
trucks with a weight of more than 3.5 tons will be reduced
10,000 kilonewtons press force
by 80%. Our customer took this opportunity to thoroughly
Destacker
revise all of their models. In the future, important
Press automation with crossbar robots
components of the new trucks will be produced on a
Unloading with crossbar robot
high-performance hydraulic press line from Schuler.
Two outfeed belts
High productivity combined with high flexibility proved to be convincing arguments.
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Press lines
Hybrid press lines
Lead press hydraulic – follow-up presses mechanical Hybrid press lines consist of a hydraulic lead press and mechanical follow-up presses. They are a cost-effective alternative when single-action and double-action dies will be used on the same line. Modern hydraulic slide drives put the output rate of hybrid lines in the region of mechanical press lines. The slide cycle of hydraulic lead presses is user-programmable, and the nominal press force of the press is fully available at any time throughout the press stroke.
Hybrid press line with hydraulic lead press and mechanical follow-up presses.
Advantages One forming system for single and double-action dies Flexible production alternative
Suitable for complex drawn parts because of the hydraulic lead press Quick and easy startup of new die sets
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Press lines / The entire world of metal forming
Press lines
Mechanical high-speed press lines
Crossbar feeder improves output performance To increase the cost-effectiveness of mechanical press lines, Schuler developed the crossbar feeder. In press lines with crossbar feeder automation, the components are transported directly from press to press without intermediate stations. If required, the components can also be repositioned before placement into the die. As compared to mechanical press lines with robot or feeder automation, it is possible to achieve production rates as high as 15 strokes / minute. In mechanical press lines with crossbar feeder automation, both the loading of press 1 as well as unloading the finished parts can be performed with the crossbar feeder.
Mechanical high-speed press line with crossbar feeder automation.
Advantages Output rate up to 15 strokes / minute
One set of tooling for each press opening
Crossbar feeder with seven degrees of freedom
Short distances between presses
No intermediate stations required
Rapid die and tooling changes
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Mechanical high-speed press lines
In practice Customer: Automobile manufacturer, People's Republic of China
Mechanical high-speed press line.
End-of-Line-System.
The requirements:
The solution:
Delivery of a fully-automated mechanical high-speed
Schuler high-speed press line.
press line. Destacker Loading press 1 with crossbar feeder Fast die change Crossbar feeder press automation End-of-Line-System with crossbar f eeder and robot Control station
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Press lines / The entire world of metal forming
Press lines
Servo press lines
Quick, compact and flexible Equipped with a Schuler destacker, crossbar feeder and End-of-Line-System, servo press lines offer the greatest possible flexibility, high output rates with a wide range of parts as well as short die and tooling change times. Using innovative drive technology, the slide movements of all presses can be individually adapted for each component, the forming process, the die and the parts transport. In identical processes, this leads to higher output rates for single, double or four-fold parts in steel, aluminum and components made from higher-strength materials. The combination of high output, short change times and high flexibility contributes to reduction of part unit costs and improvement to the productivity of press shops.
Six-stage servo press line with crossbar feeder automation.
Advantages Output rate up to 23 strokes / minute
Fully automatic die and tooling change in three minutes
High level of flexibility
One set of tooling per press opening
Reduction in part unit costs
Die tryout possible with hand wheel function
Slide movement freely programmable
User-friendly user interfaces
Optimum adaptation to various forming processes
Ergonomic parts outfeed
Automation with destacker and crossbar feeder
Easy-to-maintain technology, because the flywheel,
Compact design of the press line
clutch and brake are dispensed with
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Servo press lines
In practice Customer: Automobile manufacturer, Germany
Servo press line with six die stations.
Destacker.
Control station.
The requirements: Delivery of three servo press lines for large-scale mass production of a wide range of parts in three plants. Output performance: 17 strokes / minute. The solution: Fully automated servo press line with six die stations. Destacker with lubricating unit and optical centering station Loading press 1 with crossbar feeder Crossbar feeder press automation End-of-Line-System with robot and crossbar feeder Control station Hand wheel function for die startup Crossbar feeder simulator Die change in three minutes
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Press lines / The entire world of metal forming
Press line with ServoDirect technology. 61
06
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Automation of press lines / The entire world of metal forming
AT A GLANCE
Automation of press lines
From the single press to the complete press line: As a
Destacker for press lines
64
blank washers and lubrication units
65
Robots
66
Crossbar robot
67
Crossbar feeder
68
Part racking systems
69
system supplier, we automate your forming systems intelligently and practically. We boost the performance of your production efficiently and economically. Whether it comes to a broad portfolio of parts, high productivity or the need for a compact space, automation solutions from Schuler guarantee high efficiency and reliable production processes. When it comes to modernizing existing lines, we offer tried-and-tested practical solutions for efficient production of components in the highest quality. Automation solutions from Schuler deliver convincing performance in all aspects of forming technology.
SCHULER ONLINE Would you like to find out more about our stamping plant? You can find our »High-Speed in the Stamping Plant« focus at www.schulergroup.com/automation. In addition, you can download the »Performance along the line – Automation from Schuler« brochure as a PDF.
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Automation of press lines
Destackers for press lines
Modular designed destacker concepts for mechanical and hydraulic press lines are designed to suit downstream forming systems. Schuler offers a selection of models adapted to the required part size and contour, the type of material, the blank weight and the loading speed. From the simplest loader with one robot without centering station for small parts and simple operations, up to destackers with two destacking stations, optical or mechanical centering station, blank washers and lubrication units for large and / or heavy blanks we have it all. The blank destacking is performed by the robot or feeder. To help make full use of the capacities of large press lines, two or even four blanks can be processed at the same time. For press lines with crossbar automation, loading the first die station can be performed by a crossbar robot or crossbar feeder. In addition to handling conventional steel sheet, these destackers can also process blanks Crossbar robot automation.
in aluminum, steel-aluminum mix, and higher-strength steels.
THE BLANK COMPONENTS One or two destacking stations for separating blanks with a double blank monitor Optical or mechanical centering station Wash unit
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Lubricating unit Loading unit with robot, crossbar robot or crossbar feeder
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Automation of press lines / The entire world of metal forming
Automation of press lines
Blank washers and lubricating units
Blank washer, lubrication unit and loading robot in front of a hydraulic press line for manufacturing aluminum components.
Blank washers provide a high and consistent component quality.
Destacker with optical centering station, loading robot and blank washer.
Blank washer and
In addition, blank washers also
Depending on requirements, the
lubricating unit
provide significant reductions in
blank washers are designed to suit
Superior quality for outer skins and
downstream reworking and costs
variable blank lengths and widths.
structural parts requires blank
when it comes to body-in-white
A defined amount of oil provides
washing prior to processing to remove
assembly and painting. Blank
optimum preparation of the blank for
any dirt and deposits, and a final
washers are an integral part of
subsequent forming processes.
application of a defined amount of oil.
modern destackers and can, if
Flexibly programmable spraying
The effect of systematic washing and
required, be retrofitted to existing
heads in the lubrication unit ensure
a consistent application of oil prevents
lines.
superior part quality for forming
downtime for the entire process.
involving high drawing forces.
Advantages Superior, consistent surface quality of the components
Cost-savings for entire process
Best possible part quality, even with high drawing forces
Longer intervals between die cleaning
Increased productivity levels
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Automation of press lines
Robots
Press line with robot automation.
In addition to advanced automation solutions, such as crossbar technology, there is still a place for conventional solutions with robots. Robots are flexible since only one robot is required per press opening. Automatic changeover of robot tooling is easy.
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Loading robots position the blanks accurately in the die of the first press.
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Automation of press lines / The entire world of metal forming
Automation of press lines
Crossbar robot
The crossbar robot combines proven robot technology with the advantages of crossbar technology. This application uses a conventional industrial robot. The robot is then expanded by one feed axis and the crossbar beam provides a second axis. The horizontal motion takes place along the x-axis that is mounted on the press uprights. Programming is done at the operator's panel for the robot. The crossbar robot can be delivered with new lines or integrated into existing press lines.
Crossbar robot AXR90 Max. loading crossbar robot [kg] (part and tooling)
90
Max. throughput rate with press [strokes / min]
12 – 15
Turning horizontally
± 10°
Swiveling at right angles to the transport direction
± 25°
Swiveling in the transport direction
± 25°
The crossbar robot combines the advantages of robot technology and crossbar technology.
Advantages Direct parts transport from die to die
Complete solution including destacker and End-of-Line
Press spacings from 5 to 10 meters
Can also be used as destacker and unloader
No intermediate station
Flex, double and four-fold parts production possible
Flexible parts orientation from die to die
Suitable for steel and aluminum
No turning of components from die to die
One set of tooling per opening
User-programmable change in parts orientation
Rapid automatic tooling change
Simple programming
Ease of maintenance due to free access to the
Adapter permits takeover of the crossbar feeder tooling
press opening
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Automation of press lines
Crossbar feeder
Crossbar feeder within the press line.
Three rotating and four linear axes.
The crossbar feeder is the automation technology for
productivity of the stamping plant. The components are
high-speed mechanical and servo press lines. It increases
transported from die to die without intermediate stations
the line and process efficiency of mechanical press lines.
and can also be repositioned. The short, compact design
The crossbar feeder offers seven degrees of freedom,
makes the feeder extremely rigid.
three rotating and four linear axes, increasing the
Advantages Seven degrees of freedom
One set of tooling per press opening
Output rate up to 23 strokes / minute
Variable press spacings
No intermediate stations required
Free access to the press opening
Optionally available with feed-direction rail for large
Compact construction possible
distances between presses
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Fast die changes
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Automation of press lines / The entire world of metal forming
Automation of press lines
Part racking systems
Press line with ServoDirect technology and automatic part racking system.
Part racking systems are reliable and fast, while ensuring
Then the correction data is transferred to the robots. The
maximum part quality. A special suction-cup technology
robots pick up the finished parts in the correct orientation
protects the highly sensitive surfaces of outer skin panels
and stack them in parts containers. The automatic racking
for downstream processing and preparation for
system allows single, double and four-fold parts to be
subsequent body-in-white assembly.
stacked with a stroke rate up to 17 strokes / minute. Up to four robots are used with single parts, while there are up
Automatic part racking system for
to eight used with double and four-fold parts. The robots
servo press lines
operate in pairs and alternately stack the parts in the same
The newly-developed, automatic, flexible part racking
container in order to ensure a high output rate. The part
system from Schuler operates with hanging robots, which
racking system may also be equipped with an automatic
can also be moved on a track. The position of the finished
quality control function.
parts is detected visually by a camera system.
Advantages Stacking of single, double and four-fold parts
Compact, short design
Four-fold racking performance up to 68 parts / minute
Automatic quality control can be integrated
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Tryout systems / The entire world of metal forming
AT A GLANCE
Tryout systems
Tryout systems offer the highest level of flexibility for die making and stamping plants. Depending on the
Hydraulic die-spotting and tryout presses
72
Hydraulic Multicurve presses
73
Tryout centers
74
Tryout presses with ServoDirect technology
76
Die turnover devices and simulators
77
requirements, they contain various hydraulic or mechanical press types, die turnover devices and turntables. The time-consuming job of manually reworking the dies is carried out outside the tryout presses. The individual components of the tryout system are connected by moving bolsters on a rail system.
SCHULER ONLINE Would you like to find out more about our tryout systems? You can find our complete offer at www.schulergroup.com/hydraulic_press. There you can find a complete overview of all our system solutions.
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Tryout systems
Hydraulic die-spotting and tryout presses
Die tryout before the production startup To keep the startup costs of new die sets low, it is important to prepare them optimally for series production. Hydraulic tryout presses ensure short startup phases under near-to-production conditions. They are suitable for use in die tryout and startup prior to production getting underway. The line operator has the full press force available at any time, and can lower the upper die sensitively onto the lower die if required. In terms of sizes, performance data and equipment details, die-spotting and tryout presses are designed to meet the requirements of die tryout and pilot-series production.
Tryout center with hydraulic tryout presses.
Advantages Programmable speeds and forces Slide return possible at any point
For double-action presses: operation possible in singleaction or double-action modes
Precise slide movements using a joystick
Rigidity like production presses
Maximum force available over the entire stroke
Bed cushion technology like in production lines ensures
Simple adjustment for varying die heights
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optimum startup results
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Tryout systems / The entire world of metal forming
Tryout systems
Hydraulic Multicurve presses
Precise simulation of forming processes Hydraulic multicurve presses are used for starting up die sets in the die shop, in tryout centers and in the stamping plant. Equipped with a hydraulic accumulator drive, they simulate the slide motion characteristics of various hydraulic and mechanical production presses. To properly represent the forming processes of mechanical production lines, the hydraulic multicurve press achieves working speeds up to 500 millimeters / second. Various user-programmable slide motion curves are available to the user at any time, with any desired adjustable stroke rate. The four-point drawing cushion in the press bed is identical to that in the production press and ensures optimum startup results.
Multicurve presses with moving bolster and die turnover device.
Advantages Precise simulation of the slide movement curves of all press types
Reduction in startup times on production lines Bed cushion identical to that on the production press
Drawing speeds up to 500 millimeters / second User-friendly management of the programmable motion curves
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Tryout systems
Tryout centers
Flexible system solution in the die shop Tryout centers with a number of different press types offer an extremely high degree of flexibility in the die shop. Depending on the design, these centers may include mechanical and hydraulic die-spotting and tryout presses, die turnover devices and turntables. The time-intensive manual die rework mainly takes place outside of the tryout presses. The various pieces of equipment within the tryout center are connected by moving bolsters on a rail system. The dies can be moved into the optimum position for the required work.
Tryout center with die-spotting and tryout press.
Advantages High level of flexibility
Use of simple die-spotting presses for die-spotting work
Die startup on moving bolsters outside the presses
Optimum utilization of the equipment
Turning the upper dies with die turnover devices for ergonomic reworking from above
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Tryout systems / The entire world of metal forming
Hydraulic die-spotting and tryout presses in the die shop
In practice Customer: Automobile manufacturer, Germany
Tryout center with hydraulic tryout presses.
The slide can be moved sensitively up and down using a joystick.
The requirements:
A hydraulic multicurve press, press force:
Tryout center for die startup of series production dies.
25,000 kilonewtons With multicurve accumulator technology
The solution:
Drawing cushion in eight-point design
Tryout center with a total of twelve hydraulic tryout presses.
Three hydraulic multicurve presses, press force: 21,000 kilonewtons each
Bed and slide dimensions: 4,500 × 2,500 millimeters
With multicurve accumulator technology
Each press with moving bolster to the front, hydraulic
Drawing cushion in eight-point design
drawing cushion, hydraulic slide cushion and hydraulic impact shock dampening
Four hydraulic tryout presses, press force: 16,000 kilonewtons each Four hydraulic tryout presses, press force: 12,000 kilonewtons each
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Tryout systems
Tryout presses with ServoDirect technology
Increasing the availability of production presses Tryout presses with ServoDirect technology are configured as a duplicate of mechanical production lines. The bowing and deflection properties of the line are consistently simulated for the slide drive, connection point arrangement, spacings between uprights and bed cushions. This means the availability of production operation can be increased even further. The hand wheel function in particular offers the press operator new possibilities when starting up new dies. The servo drive allows optimum simulation of the movement properties of an extremely wide range of presses.
Tryout presses increase availability in the press shop.
Advantages Simulation of the production conditions of mechanical presses Increased availability in production
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Reduced parts costs per stroke Slide tilting is identical to production presses Takeover of die data
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Tryout systems / The entire world of metal forming
Tryout systems
Die turnover devices and simulators
Die turnover device for easy turning of upper dies.
Simulator device for crossbar feeder.
Die turnover device – Ergonomical DIE REWORK
Simulators – precise setup of
For ergonomic rework of upper dies in the tryout phase, it
automation equipment
is preferable to turn them to an ergonomically favorable
At the interface between the die shop and stamping
position. Die turnover devices are used for safe opening and
plant, tryout presses and simulators both play a role
turning, and can be connected to the tryout presses using
in preparing dies and automation devices for series
moving bolsters. Die turnover devices simplify die
production while the production continues without
handling, so that the dies are subsequently available to
interruption. The component transport is simulated and
the production presses more quickly.
optimized in order to reduce cost-intensive setup phases on the production presses.
THE ADVANTAGES Simple opening and turning of the dies
THE ADVANTAGES
Ergonomic rework of the turned dies
Simulation of the automation while production continues
Integration into tryout centers using rail systems
Shortening of changeover and startup times
and moving bolsters
Increased press uptimes Training of employees while production continues
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Lightweight technologies / The entire world of metal forming
AT A GLANCE
Lightweight construction technologies
Nowadays, it is technically feasible to build a light and safe
Press hardening with PCH technology
80
Press hardening technology center
83
Cold forming of high-strength steels
84
Aluminum forming
85
Forming of fiber-reinforced plastics
86
Hydroforming
87
car, but the manufacturing costs are a factor. Some particularly light and low-consumption car models did not attract enough buyers in the past, because they were too expensive for customers. In the future, there cannot be simply one basic approach to achieving greater efficiency. What are called for are different concepts according to individual customer requirements and vehicle categories. It is only through the interplay of several processes and the use of different materials that the required success can be achieved in lightweight construction. Each material has specific strengths, and is therefore suited to different installation areas in the car.
SCHULER ONLINE Would you like to find out more about pressure-controlled hardening (PCH) in the forming process? You can find further information at www.schulergroup.com/forming_systems. In addition, you can download various brochures on the topic from there, or view an explanatory film.
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Lightweight construction technologies
Press hardening with PCH technology
PCH Hardline Multi press hardening line. 80
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Lightweight technologies / The entire world of metal forming
Sustainably successful Schuler makes cars lighter. The results are: lower fuel consumption and CO2 emissions. The greatest saving
potential available in today's passenger cars are to be found in the bodywork and running gear, which together comprise about 65 percent of the vehicle's mass. Perfectly built, quality components for the chassis, engine and bodywork not only make cars look attractive, they also guarantee safety and comfort. Press hardening with Pressure Controlled Hardening (PCH) technology is the basis for higher body rigidity – significantly improving crash behavior. In press hardening, high-strength safety components are manufactured by heating the blank, then forming in a hydraulic press with rapid cooling in the die. Steels with initial strengths of 500 to 700 newtons / square millimeter achieve ultimate strengths of 1300 to 1600 newtons / square millimeter.
Press hardening of safety components in large-scale production.
The component spectrum of press hardening: Side impact elements and B-pillars Side sill plates Roof frames Support parts Tunnel Door frame reinforcements Bumpers
Advantages Higher strengths with reduced component weight
Good repeat accuracy without spring-back
Higher rigidity of the bodywork
Less expensive material compared to high-strength steels
Improved crash behavior
No high press forces required
New possibilities in component design
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Press hardening Yesterday
Today
Simple press technology
Innovative press technology
Presses without cushion technology
Presses with cushion technology
Functions integrated in the die
Functions integrated in the press
Part quality mainly dependent on the die
Part quality can be improved
Only limited process control Long cool-down times Max. production rate 2 parts / stroke Robot or feeder automation Average production rate 4 to 6 parts / minute
Press hardening die for series production.
High cost for dies
Control of important processes possible Short cool-down times Max. production rate up to 4 parts / stroke High-speed transfer automation Average production rate 12 to 24 parts / minute Lower cost for dies
The press hardening performance range Forming simulation
- Centering station
- Laser equipment
Die design and construction
- Robot or transfer automation
- Finished part handling
System engineering and installation
- Integration of furnace technology
- Master controller
- Destacker
- Blanking presses and dies
- Hydraulic press technology
- Soft-Shock technology
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Lightweight technologies / The entire world of metal forming
Lightweight construction technologies
Press hardening technology center
Test stand for further development of the press-hardening process.
Fast twin-feeder automation.
Center of competence for press hardening The center of competence is where Schuler brings together
The current developments in modern steel materials are
its entire process and machine expertise relating to press
also incorporated into creating future-oriented system
hardening, offering not only machine construction but
solutions. Development goals include shortening cycle
consulting across the entire process. Here, the process
times, optimizing the process and thus reducing the costs
is continuously developed by experts from process
per component. Furthermore, the specialists are working
engineering, press construction, die and automation
on continuous improvements to component quality and
technology for applications in automotive series production.
increasing the flexibility of system solutions.
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Lightweight construction technologies
Cold forming of high-strength steels
Innovative lightweight vehicle manufacture is now inconceivable without high-strength steels, and applications in mass production will increase in coming years. It is possible to achieve further reductions in sheet thicknesses by using new, high and extra high-strength steels while maintaining the same component properties. This means a lighter weight and reduced costs. ServoDirect technology is pointing the way to the future Press lines, transfer and prog-die presses as well as blanking systems with ServoDirect technology have significantly changed stamping plants. They are characterized by maximum flexibility, high output and short die change times. The slide movement of each press for each component can be individually adapted to the forming process, the die and the automation. This ServoDirect press for cold-forming high-strength steels.
is opening up new possibilities for cold forming of high-strength steels. New processes – new possibilities Using the advantages of ServoDirect technology, Schuler is developing new production concepts for manufacturing lighter components. For example, interdisciplinary teams are looking into the possibility of integrating follow-on processes or adopting new approaches for manufacturing hybrid components. The objective is to develop new production processes that can meet all the requirements of series production despite the conflicting objectives of reduced component weight, efficient production and high safety requirements.
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Lightweight technologies / The entire world of metal forming
Lightweight construction technologies
Aluminum forming
Aluminum has now become a standard material in the area of hang-on parts in many vehicle types. The material can significantly reduce the weight of a body-in-white, even if it is only rarely entirely made by forming aluminum. Nowadays, about 40 percent of the overall weight of a car is accounted for by the body. The trend for an increasing variety of materials means aluminum is being used to an increasing extent in automobile production. From the skin through to the front wing and bonnet – aluminum is being used more and more frequently in modern, reduced-weight vehicle manufacture because these applications are often selected as a means of replacing heavier materials. Thanks to its unique energy absorption ability, it can also save lives in case of a collision. Lower fuel consumption, greater comfort and performance are further arguments alongside that of Hydraulic press lines for manufacturing aluminum components.
increased safety for the use of aluminum as a material. Schuler develops mechanical and hydraulic press lines as turnkey solutions for processing aluminum skin panels. We order suitable retrofit solutions for existing production systems. Our turnkey machines have all of their components designed for the materials they will process, from automation through to the press and die.
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Lightweight construction technologies
Forming of fiber-reinforced plastics
Fiber-reinforced plastics offer a great deal of design freedom and a wide range of functions with minimum component weight. They represent new, lightweight concepts in vehicle architecture and in bodywork manufacture. Schuler builds fully automated hydraulic press systems for efficient and reliable series production of fiber-reinforced components, that can withstand even the most demanding component and production requirements. Hydraulic press systems from Schuler are suitable for series production of SMC (sheet moulding compound) components, GMT (glass mat thermoplastics) components, LFT (long fiber-reinforced thermoplastics) components and RTM (resin transfer moulding) components. Different systems are used for these, depending on the component requirements and the production process. Robot-automated production of fiber-reinforced plastic components.
The result is: Best parts quality and highest production reliability – for greater efficiency and maximum productivity.
Hydraulic presses for fiber-reinforced plastics Press force [kN] 12,500
16,000
21,000
25,000
30,000
36,000
Press force with max. parallel 10,500 control force [kN]
14,000
18,000
22,000
26,000
32,000
Bed size [mm] 2,800 × 1,800
2,800 × 1,800
3,000 × 2,000
3,200 × 2,200
3,400 × 2,400
3,600 × 2,400
Slide stroke [mm] 1,600
1,600
1,800
1,800
1,800
1,800
Shut height [mm] 2,200
2,200
2,600
2,600
2,600
2,600
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Lightweight technologies / The entire world of metal forming
Lightweight construction technologies
Hydroforming
Fully automatic tubular forming machine at a German automobile manufacturer.
Tubular hydroforming of longitudinal members.
Tubular hydroforming offers a wide variety of
Schuler offers its partners not only elaborate systems
opportunities. Above all, however, it is used in series
and integration solutions but also component analyses,
production of automobiles, since this is where particularly
feasibility studies, prototype and die construction all
high requirements in terms of component composition
from a single source.
and component design need to be met. The process is used for, among other things, forming exhaust, chassis and structural parts.
Advantages High component rigidity and strength
Maximum repeat accuracy
Low component weight by optimized design without
High component quality and long service life by avoiding
material duplications Best exploitation of material Integration of additional functions in the components
welds and having a geometry optimized with regard to function High freedom of design for complex components
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Process technology / The entire world of metal forming
Process technology
Consistent performance
Targeted support To be prepared for the challenges of the future, we tackle them with efficient structures. By establishing our own Process Technology department, we have reoriented ourselves strategically, and are now capable of supporting you in an even more targeted and consistent way. For example, we are excellently prepared to expand our range of services and products to include new ideas and innovative concepts. That is the basis for future success together: after all, your success is our success! The product development process is our key area of expertise. Whether you are looking for a complete solution or a partial one – with our knowledge of the entire process cycle, we can offer you inestimable advantages for your production.
Set of consecutive steps.
Successful together with all Schuler technologies
Automotive Press Technology
Stamping & Cutting Technology
Forging Technology
Hydraulic Press Technology
Highspeed Technology
Automation Technology
Mechanical processing
Assembly
Process Technology
Feasibility & simulation
Method & production concepts
Design
Model making
Tryout
Stamping plants
Training & Startup support
Equipment in Quality
Multi-disciplinary technological process team
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Success can be programmed. After all, perfectly matching processes are required for producing components in the best quality and with maximum output rates.
Transfer die for manufacturing disk carriers.
Engineering performance spectrum
Range of die services
Method planning / simulation
Body dies for
Feasibility analyses
Skin panels
Creation of methods and drawing systems
Structural parts
Process layout creation
Press hardening dies for structural parts
Deep-drawing simulation including simulation of the follow-up stations
Powertrain dies for
Springback calculation
Disk carriers
Active surface creation
Spiders
Crowning and overpressure points
Guide disks Thrust washers
Design Simulation of dies and press sequences
Modular dies for
Drawing and forming dies
Welding modules
Trimming / perforating dies
Friction modules
Progressive dies, Transfer dies
Piercing nut modules
Folding dies
Laser modules
Mechanization systems
Solid plate forming module
Model making
Progressive / transfer dies for
Drawing system production
Structural parts for prototype and ultra-small
Casting models for die making Casting models for general engineering 90
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Process technology / The entire world of metal forming
New press generation TST – TwinServo Technology at the UmformCenter Erfurt.
Göppingen stamping plant.
Parts production performance range
At our stamping plants in Göppingen and Erfurt, we offer the following services: Startup as well as
Göppingen stamping plant
process and quality optimization, temporary part
Skin panels
pressing operations, small-series production and
Structural parts
series production.
Schuler Forming Center Erfurt Disk carriers Guide disks Spiders Structural parts
From simulation through to series production Thanks to our core expertise in engineering, method, model and die making as well as tryout, we meet the ever increasing needs of the automotive and components industries with intelligent, complete solutions.
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Systems for large pipe manufacture / The entire world of metal forming
AT A GLANCE
Systems for large pipe manufacture
With Schuler, you lay the foundations for success with
SPIRAL PIPE PRODUCTION SYSTEMS
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System solutions for longitudinally welded LARGE PIPES
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economic, efficient and high-output production of spirally and longitudinally welded large pipes. On your behalf, we develop turnkey production lines for large pipes – whether pipelines for crude oil, natural gas, water or large pipes in the petrochemicals industry, for use in wind turbines or in the construction industry. Not only do we offer the necessary experience, we also provide the appropriate worldwide service for any required solution and projects of all scales. We ensure that we maintain our position of leadership in quality by permanent innovations and investments in research and development. At Schuler, we regard turnkey solutions for manufacturing large pipes as a highly integrated overall concept: From innovative layouts and designs through to intelligent production principles. Our goal is for you to be able to produce in an environmentally friendly way, minimizing your use of resources. In this way, you can benefit during every phase from our extensive, groundbreaking expertise in large pipe manufacture and from our competence.
SCHULER online Would you like to find out more about our system solutions for large pipe manufacture? You can find our complete selection at www.schulergroup.com/large_pipes. In addition, you can download the »System Solutions for the Manufacture of Large Pipes« brochure as a PDF file.
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Systems for large pipe manufacture
SPIRAL PIPE PRODUCTION MACHINES
Online process Combined forming and welding machine The pipe forming is directly followed by submerged arc welding from the inside and outside. Offline process Separate forming and welding machine After pipe forming and subsequent tack welding, the submerged arc welding process is performed from the inside and the outside on separate welding stands; speeds up to 12 meters / minute Modernization Conversion of existing online machines to the offline process The objectives of such a conversion of existing machines are to increase quality and productivity as well as Spiral pipe production machine.
improving safety at work and energy efficiency.
We plan and implement complete production plants for
Suitable for spiral pipes with
manufacturing spirally welded large pipes, making them
Length up to 24 meters
turnkey for you. The machines meet the most demanding
Diameter from 450 to 3500 millimeter (18 "– 140 ")
Technical data
requirements in terms of diameter tolerances or welding
Wall thickness from 6 to 25 millimeters (1 / 4 " – 1 ")
gap, as well as impressing with maximum availability
Other dimensions possible on request.
and productivity. Schuler offers progressive and highperformance solutions, precisely adapted to your
the advantages
requirement profile and tailor-made to your specific
Automation of important working steps
requirements – from planning and consulting through
Increased safety at work
to startup.
Low downtimes High process reliability Reproducible, high product quality Planning and implementation of complete production lines
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Systems for large pipe manufacture / The entire world of metal forming
Hydrotester.
Coil preparation stand.
End beveling machine.
Hydrotester
Coil preparation stand
End beveling machine
Ball head mounted inside sealing
Schuler ensures a significant
Automatic clamping with correct
or face sealing
simplification in handling during the
force according to the diameter
Water hydraulic control system
coil change – at the same time as
Variable holding time
improving quality and optimizing
Connected to PID data system
procedures. Not only does this enable
Short changeover time
Automatic pipe positioning
you to reduce unproductive down-
Concentric clamping
Automatic test sequence
times, it also ensures consistently
Energy recovery by using the
Visualization with database for
higher efficiency throughout the
all pipe parameters
Infinitely coverage for all diameter ranges
latest inverter technology
production process. Furthermore,
Full automatic pipe feeding
you sustainably increase the safety of work on the stand.
Pipe diameter [inch]
18 – 140
Coil weight max. [t]
45
Pipe length [m]
8 – 24
Closing force [kN]
max. 50,000*
External coil diameter [mm]
1,300 – 2,200
Internal coil diameter [mm]
720 – 800
Coil width [mm]
1,000 – 2,050
Coil thickness [mm]
6 – 25.4
Water pressure max. [bar] High-pressure control range [liter / min]
400 33 – 300
* Higher closing forces on request.
Cutting speed max. [m / min]
90
Face plate feed speed [mm / min]
5 – 50
Face plate drive servomotor max. [kW AC]
200
Speed [m / min] Coil unwinding
0.3 – 6.0
Plasma cutter
0.1 – 3.0
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Systems for large pipe manufacture
LONGITUDINALLY WELDED LARGE PIPES
formed either using a bending element or with a broad bending shoe. This ensures fast and efficient production. Process for high production output U-O-presses primarily represent a solution when the highest possible production output of a particular pipe dimension range is to be achieved. As with the bending presses, the C-press is also configured as the crimping press for pipe forming; together with the tacking press it ensures consistent pipe forming, while this concept provides optimum passage through all the individual pipe production stations. Modernizations Presses and machines from Schuler are particularly suitable for complete modernization concepts or exchanging individual system components in existing Large pipe production machine.
pipe plants.
Regardless of whether your machine should be designed
Suitable for longitudinally welded large pipes with
Technical data for longitudinally welded large pipes with a bending press
Length up to 18.3 meters (60 ')
or with U-O-presses – Schuler provides you with the
Diameter from 406 to 1625 millimeters (16 "– 64 ")
innovative and forward-looking production technolgy. We
Wall thickness 12 to 70 millimeters (0.48 " – 2.76 ")
adapt and individually tailor our presses to your product
Other dimensions possible on request.
dimensions. Not only are we your expert for efficient modernizations in order to optimize the performance of
the advantages
existing pipe plants, we are also the ideal technology
Planning and implementation of complete
partner for complete turnkey solutions. Whichever
production lines
approach you take – the best idea is to get the expertise
Matching processes and process sequences
and experience of Schuler on your side right from
High process reliability
the outset.
Reproducible, high product quality High level of automation
Step process for flexible production
Safeguarded high availability
Schuler bending presses (step process) are universally
Energy-efficient hydraulic drives EHF
applicable for pipes with diameters from 406 mm to
Global service network
1625 mm (16 " – 64 "). Pipes in this dimension range can be
Security of investment by turnkey solutions
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LFJ-pipe forming press.
Systems for large pipe manufacture / The entire world of metal forming
U-O press.
LFJ pipe forming press
U-O presses
The modular LFJ pipe forming press is a further
The particular advantage of the U-O process is its high
development of the conventional pipe forming press. This
production output of pipes with one set of dimensions. The
unique development means that Schuler has an exclusive
individual forming steps are adapted to this in order to
and attractive product highlight in its portfolio. It is
produce a good quality open-seam pipe. In this way, the
characterized by an almost direct sheet feed, and bowing
subsequent production steps can be carried out optimally.
compensation is not required. The modular structure ensures straightforward transport and input into the
the advantages
press without difficulty.
High productivity for set pipe dimension Optimized die setting
the advantages
Simple integration into existing production lines
High productivity because the panel is loaded at the
Modernization option for existing machines
same time as the open-seam pipe is unloaded
Comprehensive, tried-and-tested operating concept
High productivity because bending shoes can be used High flexibility by using the bending element High process reliability by simplified press design Simple transport and trouble-free integration into existing production lines because of modular structure Simple structure with scope for future uprating by extension for bending longer pipes Automatic die change and die adjustment available as an option
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Sites and Schuler service
At a glance
Sites and Schuler service
Technologies, systems and machines from Schuler are at
Partners for sheet metal forming
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Schuler Service
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home in the following sectors: automotive, tier 1 - 3, appliances, minting, packaging, drives & generators, railway, aerospace and large pipes. Developing solutions for these industries requires us to do the following: reduce good concepts to a common denominator. With the objective of coming even closer to our customers and taking account of different industry requirements. Therefore, we supply you with not only press technology but also intelligent system solutions which meet the requirements of the global competitive environment. The individual requirements of users in the particular market environment are the center of our attention. In this way, we convert technological leadership into specific customer benefits, and together with you we wish to take advantage of technological and growth opportunities. For this purpose, the Schuler Group employs about 5,500 people and has its own sites / agencies in 40 countries. We are your reliable partner who supports you worldwide. Benefit from the extensive expertise of our project teams in installations all over the world. We are there for you.
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Addresses
PARTNERS FOR SHEET METAL FORMING
15
Schuler Group headquarters, Göppingen.
Schuler AG
13
GERMANY
Bahnhofstrasse 41 73033 Göppingen Tel. +49 7161 66 - 0 Fax +49 7161 66 -233
[email protected]
1
www.schulergroup.com Schuler service
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www.schulergroup.com/service
Schuler service and production sites Schuler Service
SCHULER ONLINE We employ about 5,500 people worldwide at our own sites and agencies in 40 countries, so we are always in your vicinity. How to contact us. For an overview of all our sites and the most important address information, refer to the Internet at www.schulergroup.com/plant_locations.
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Addresses
9 3 5 2
6 4
7
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1. Germany 2. France 3. United Kingdom 4. Italy 5. Poland 6. Switzerland 7. Slovak Republic 8. Spain 9. Russian Federation 10. Brazil 11. People's Republic of China 12. India 13. Mexico 14. Thailand 15. USA
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Social media Current information about Schuler is available on Facebook, YouTube, Xing, Twitter and LinkedIn. The footer at the bottom right of our webpage www.schulergroup.com contains links to our activities. You can visit us on the Internet. We are looking forward to seeing you.
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Schuler service. Optimum Service fOr mOre perfOrmance.
Schuler Service offers a tailored portfolio of services covering the entire life cycle of your equipment.
Schuler Service – Customer-oriented, efficient, worldwide.
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Over 900 service employees worldwide provide expert
components and Accessories:
support 24/7 in close cooperation with you – our partners.
Spare parts and spare part packages
Our main priority is always to ensure the ultimate produc-
Maintenance kits
tivity and safety of your production equipment in order to
Repair parts
secure your company’s continued success.
Replacement parts
With over 170 years of experience and expertise, we can
Project Business:
guarantee the best possible support for the operation of
Modernization
your machines – and not only those supplied by Schuler, but
Retrofits
by all other manufacturers. Whatever the situation, Schuler
Refurbishment
Service has the right solution for your specific needs.
Machine relocations special services:
Our services fOr yOu.
Service contracts Hotline and remote service
Technical customer support:
Training
Machine inspections
Tailored customer training
Safety inspections
Optimizing plant & processes
Preventive maintenance
Consulting
Repair Repair welding
used Machinery:
Production support
Purchase and sale Evaluation
schuler service ONliNe Want to know more about our full range of services? Simply scan the QR code with the camera of your smartphone or tablet. www.schulergroup.com/service
Find out more. Simply scan the QR code using the camera of your smartphone or tablet.
Schuler AG Bahnhofstraße 41 73033 Göppingen | Germany Phone +49 7161 66 - 0 Fax +49 7161 66 -233
[email protected] [email protected] www.schulergroup.com
www.schulergroup.com/sheetforming
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